Catalytic Converter: Service and Repair

Catalytic Converter Replacement (RWD)

Removal Procedure

Caution:
^ Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.
^ In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components.





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Support the catalytic converter assembly.
3. Remove the 3 oxygen sensor electrical connections and clips.





4. Remove the nuts from the muffler flange bolts.





5. Remove the nuts from the exhaust manifold studs (right side).
6. Disconnect the collars from the exhaust manifold studs (right side).





7. Remove the nuts from the exhaust manifold studs (left side).
8. Disconnect the collars from the exhaust manifold studs (left side).





9. Remove the catalytic converter assembly from the muffler assembly.
10. Remove the catalytic converter assembly from the exhaust manifolds.
11. Lower the front of the catalytic converter assembly.





12. Remove the catalytic converter assembly from the hanger.

Notice: Do not damage the oxygen sensors when removing the catalytic converter.

13. Remove the catalytic converter assembly from the vehicle by rotating the assembly over the rear of the transmission crossmember.
14. Remove the 3 oxygen sensors.

Installation Procedure





When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear.
In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps.

Important:
^ Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed.
^ When exhaust system service requires removing and replacing an oxygen sensor, refer to the applicable service procedure.
^ Always use new nuts when installing the exhaust pipe to the exhaust manifold.
^ Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush.

1. Install the 3 oxygen sensors to the catalytic converter assembly.
2. Install the catalytic converter assembly to the hanger.





3. Install the collars on the catalytic converter assembly to the exhaust manifold studs (left side).
4. Loosely install the nuts onto the exhaust manifold studs (left side).





5. Install the collars on the catalytic converter assembly to the exhaust manifold studs (right side).
6. Loosely install the nuts onto the exhaust manifold studs (right side).





7. Connect the catalytic converter assembly and the gasket to the muffler assembly.
8. Loosely install the nuts.

Notice: Refer to Fastener Notice in Service Precautions.





9. Tighten the exhaust manifold nuts in proper sequence (1-6).
^ Tighten the catalytic converter assembly-to-exhaust manifold nuts to 53 Nm (39 ft. lbs.).
^ Tighten the catalytic converter assembly-to-muffler assembly nuts to 40 Nm (30 ft. lbs.).





10. Install the three oxygen sensor electrical connections and clips.
11. Remove the support from the catalytic converter assembly.
12. Lower the vehicle.